Method and apparatus for producing wearing article

ABSTRACT

An apparatus and method for producing a wearing article of the present invention includes supplying an elastic member; stretching the elastic member; placing the stretched elastic member so that the elastic member spreads across a plurality of first webs divided in a transport direction; making a part of a second web loose in the transport direction while transporting the second web, thereby forming a loose portion; placing the first web, on which the elastic member is disposed, on non-loose portion before and after the loose portion of the second web; and cutting the elastic member between adjacent first webs of the plurality of first webs.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of commonly assigned,copending application Ser. No. 10/316,523, filed Dec. 11, 2002, andentitled “Method and Apparatus for Producing Wearing Article”, theentire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method and apparatus for producing adisposable wearing article such as paper diapers and pants.

2. Description of the Related Art

In the above-mentioned type of wearing articles, in order to form, forexample, a waist gathering, an elastic member is placed on a sheetsurface. However, such an elastic member allows an absorber to shrink,so that the absorber becomes stiff, degrading a feeling of wearing.

As a prior art of cutting an elastic member, Japanese Laid-Open PatentPublication No. 2001-224627 discloses a method for interposing a filmsheet for gathering between a peripheral surface of an adsorbent rollerand a cutter blade of a cutter roller, and cutting the film sheet.

Furthermore, International publication No. WO 00/04855 discloses amethod for forming a web loop.

SUMMARY OF THE INVENTION

In order to achieve the above-mentioned object, a method for producing awearing article of the present invention includes the steps of:supplying an elastic member; stretching the elastic member; placing thestretched elastic member so that the elastic member spreads across aplurality of first webs divided in a transport direction; making a partof a second web loose in the transport direction while transporting thesecond web, thereby forming a loose portion; placing the first webs, onwhich the elastic member is disposed, on non-loose portions before andafter the loose portion of the second web; and cutting the elasticmember between adjacent first webs of the plurality of first webs.

According to the present invention, the loose portion formed in thesecond web may be folded into two to form a folded portion. Furthermore,after the first webs are placed, and before and/or after the elasticmember is cut, the loose portion of the second web is stretched so as toposition the first webs away from each other.

According to the present invention, a method for folding the second webmay include the steps of: using a rotation apparatus provided with aplurality of pads which are rotated to continuously transport the secondweb, thereby supplying the second web to surfaces of the pads with apredetermined interval; allowing the pads to hold the second web on thesurfaces of the pads; changing the interval between the adjacent padssupplied with the second web; folding a part of the second web bydecreasing the interval between the adjacent pads to make the second webbetween the adjacent pads loose; and releasing the second web from thepads.

A production apparatus for realizing the production method according tothe present invention may includes: a roller for supplying a pluralityof first webs divided in a transport direction at a predeterminedposition in a state where an elastic member is placed so as to spreadacross the first webs; a rotation apparatus including a plurality ofpads which are rotated to continuously transport a second web andapproach the roller at the predetermined position; and a cutter forcutting the elastic member. In this apparatus, the respective pads ofthe rotation apparatus have varying circumferential velocities, therespective pads of the rotation apparatus receive the second web at areceiving position upstream from the predetermined position, and afterreceiving, an interval between the adjacent pads is decreased while thepads are rotated to the predetermined position, whereby a loose portionis formed in the second web, the first webs are placed to be stacked ona surface of the second web on a basis of the pads at the predeterminedposition, an interval between the adjacent pads is increased while therespective pads of the rotation apparatus are rotated from thepredetermined position to a releasing position downstream from thepredetermined position, and the cutter cuts the elastic member in theloose portion while the pads are rotated from the predetermined positionto the releasing position.

Another method for folding a web may include the steps of: using arotation apparatus provided with a plurality of pads which are rotatedaround a predetermined center axis to continuously transport the web,thereby supplying the web to the surfaces of the pads of the rotationapparatus; rotating the adjacent pads supplied with the web at differentvelocities to change an interval between the pads, thereby making theweb between the pads loose; folding the loose web between the adjacentpads; and releasing the web from the pads.

As the rotation apparatus, for example, a rotation apparatus describedin U.S. patent application Ser. No. 09/889,275 may be used. A rotationapparatus disclosed in U.S. patent application Publication No.US2002/0103468 may also be used. The disclosures of these areincorporated herein by reference.

According to the present invention, an absorber may be placed between aplurality of first webs with the elastic member cut therebetween. Inthis case, a shrinking force does not act on an absorber, so that theabsorber does not become stiff.

As the elastic member in the present invention, a material containingthread rubber, flat rubber, mesh-shaped rubber, a film, or athermoplastic elastic member may be adopted. As a material containing athermoplastic elastic member, hot-melt resin is considered.Furthermore,a plurality of holes or slits may be formed in a film.

According to the present invention, the elastic member may be cut with alight cutter. The light cutter may cut the elastic member by irradiatingthe elastic member between the plurality of first webs with infraredrays and UV-rays. Furthermore,the elastic member may be cut with anultrasonic wave.

The wearing article may include products or semi-finished products of awearing article such as disposable diapers, disposable pants, bandagesor the like. The wearing article may further include a single body and astack of sheets such as fabric, non-woven fabric, a liquid-transparentsheet, or a non-liquid-transparent sheet.

Another production method of the present invention may include the stepsof: continuously receiving a stacked web on each pad of a deceleratingdrum in a state where the web is stretched in a flow direction; afterreceiving the web, decreasing a circumferential velocity of therespective pads that have received the web so as to make an intervalbetween the respective pads narrow, thereby forming a shrunk portionwhere the web shrinks between the pads, and holding an edge of the webon the respective pads to keep a state where the held edge is stretched;receiving the web onto a main drum from the decelerating drum in a mixedstate where the stretched edge and the shrunk portion are presentalternately, and transporting the web while keeping the mixed state; andpressing and heating a part or an entire of the edge by a pressing andheating member on the main drum.

The heat capacity of the stretched edge of the web is small. Therefore,a transport velocity of the web is increased by heating the edge,whereby a transport amount per unit time can be increased. In otherwords, a heating time for heating the edge can be prolonged inaccordance with a ratio at which the edge of the web is stretched.Therefore, even when the transport velocity of the web is large,heat-sealing can be conducted exactly.

These and other advantages of the present invention will become apparentto those skilled in the art upon reading and understanding the followingdetailed description with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side layout view of an apparatus for producing a wearingarticle of Embodiment 1 according to the present invention.

FIG. 2 is a side layout view illustrating the steps of cutting anelastic member in the apparatus shown in FIG. 1.

FIG. 3A is a perspective view of a stack in a state before the elasticmember is cut, and FIG. 3B is a perspective view of a stack in a stateafter the elastic member is cut.

FIG. 4A is a front view showing the stack in which the elastic memberinterposed between webs is cut, and FIG. 4B is a front view showing awearing article.

FIGS. 5A and 5B are partial side views showing a circumferentialvelocity of pads.

FIG. 6 is a side layout view showing an apparatus for producing awearing article of Embodiment 2 according to the present invention.

FIG. 7 is a front view showing webs in a state where the elastic memberis placed.

FIG. 8 is a front view showing webs in a state where an absorber isattached.

FIG. 9A shows webs whose both edges are bent, and FIG. 9B shows websfolded into two.

FIGS. 10A to 10F are front views illustrating a method for placing asecond elastic member.

FIGS. 11A to 11C show an example of cutting the elastic member with acutting machine, and FIG. 11D shows another cutting machine.

FIG. 12 shows diapers obtained by cutting the elastic member so that atrim is not generated, and shifting the phase of one web thus cut bysubstantially ½ from the other web.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the present invention will be described by way ofillustrative embodiments with reference to the drawings.

Embodiment 1

FIGS. 1 to 5A-B show Embodiment 1.

An apparatus for producing a wearing article shown in FIG. 1 is capableof providing a web with looseness and intermittently placing an elasticmember on at least a part of the web. For example, the apparatus forproducing a wearing article includes a rotation apparatus 1 capable ofproviding a second web W2 with looseness and a second roller 12 capableof placing an elastic member F on portions of the second web W2 otherthan those which are loose. When the elastic member F extending across aloose portion of the second web W2 is cut with at least one of a laser,an industrial light, a blade, and scissors, the apparatus canintermittently place the elastic member F on the second web W2. Thisintermittent placement is mainly caused by the looseness of the secondweb W2. Hereinafter, the configuration and operation of the rotationapparatus 1, the second roller 12, and the like will be described.

In FIG. 1, a supply apparatus 3 of the elastic member F supplies theelastic member F to the surface of a first roller 11. The elastic memberF on the first roller 11 is fed to the second roller 12. Acircumferential velocity V2 of the second roller 12 is set to be largerthan a circumferential velocity V1 of the first roller 11. Therefore,the elastic member F is stretched between the first roller 11 and thesecond roller 12.

The second roller 12 is supplied with a first web W1. The second roller12 transports the first web W1 while sucking the first web W1 by vacuumsuction or the like. On the surface of the second roller 12, forexample, a number of suction holes 12 a for sucking the first web W1 maybe provided. After the first web W1 is sucked to be held on the surfaceof the second roller 12 by vacuum suction or the like, the first web W1is divided into a predetermined size with a web cutter 2. In thisdivision, the first web W1 may be cut or half-cut to a predeterminedlength in a transport direction. In the case where the first web W1 ishalf-cut, the first web W1 may be cut to a predetermined length togetherwith the elastic member F in a subsequent step or cut in a predeterminedlength when an interval of pads is increased. After this division, theelastic member F is placed so as to spread across the surface of therespective first webs W1. In the case where the elastic member F is madeof thread rubber or flat rubber, an adhesive is applied to at least oneof the elastic member F, the first web W1, and the second web.

It may also be possible that after the elastic member F is placed on thefirst web W1, the elastic member F is cut together with the first webW1. Furthermore, in the case where the elastic member F is made ofhot-melt resin, molten resin discharged from the supply apparatus 3 iscooled by the first roller 11. The molten resin may be cooled with coolwater. Furthermore, the first roller 11 may be a porous roller. In thecase where the first roller 11 is a porous roller, the first roller 11may be configured so that air is discharged from the inside of the firstroller 11 through holes. Due to the air, the hot-melt resin becomesunlikely to adhere to the roller. When the air is discharged from theporous body, the volume of the air is increased to cool the roller.Thus, the hot-melt resin can be cooled. The porous roller may be formedby sintering stainless ball or the like.

Furthermore, it may also be possible that the first roller 11 is beprovided with grooves or the like, whereby resin is molded. For example,mesh-shaped (for example, lattice-shaped) grooves are formed on thefirst roller 11, and hot-melt resin is applied to the grooves of thefirst roller 11 with a coater or the like, whereby a mesh-shaped elasticmember is formed.

When hot-melt resin having a softening point lower than that of Lycra®is used as the elastic member, the subsequent cutting step becomeseasier, compared with the case of using Lycra®.

The rotation apparatus 1 for folding is placed in the vicinity of thesecond roller 12. The rotation apparatus 1 has a plurality of pads 9capable of sucking the second web W2 and transporting it. On the surfaceof a pad 9 _(i), suction holes 10 for sucking the second web W2 areprovided. The rotation apparatus 1 continuously transports the secondweb W2, and is in contact with the surface of the second roller 12 viathe first web W1, the elastic member F, and the second web W2 at acontact point 0 (predetermined position). Thereafter, the following mayalso be possible: an additional roller and the pad 9 _(i) sandwich thefirst web W1, the elastic member F, and the second web W2 placed on thepad 9 _(i), whereby the contact therebetween is enhanced.

The elastic member F is cut after being interposed between the first webW1 and the second web W2. The elastic member F is fixed between the websW1 and W2, so that the elastic member F shrinks less, compared with thecase where the elastic member F is placed on one web.

The rotation apparatus 1 receives the second web W2 at a circumferentialvelocity V11 at a receiving position RP. At a point “A” where the pad 9_(i) receives the second web W2, the circumferential velocity of the padis V11. FIG. 5A is a side view showing the enlarged vicinity of thepoint “A” of FIG. 1. During a period from a time when at least a part ofthe pad 9 _(i+1) shown in FIG. 5A receives the second web W2 to a timewhen at least a part of the pad 9 _(i) adjacent to the pad 9 _(i+1)receives the second web W2, the pad 9 _(i+1) moves at a substantiallyconstant circumferential velocity V11. The reason for this is to preventthe second web W2 from being damaged.

Each pad 9 _(i) of the rotation apparatus 1 is rotated at the receivingposition RP at the circumferential velocity V11, and decelerates to acircumferential velocity V21 before reaching the contact point 0 (wherethe distance between the pad 9 _(i) and the pad 9 _(i+1) becomesminimum). Therefore, the interval between the pad 9 _(i) and the pad 9_(i+1) becomes narrow before the pad 9 _(i) moves from the receivingposition RP to the contact point 0. This causes the second web W2 tobecome loose between the pad 9 _(i) and the pad 9 _(i+1), whereby aloose portion Wa is formed.

The pad 9 _(i) comes into contact with the second roller 12 via thesecond web W2 and the like at the circumferential velocity V21 (V11>V21)at the contact point 0 shown in FIG. 1. The first web W1 is transferredfrom the second roller 12 at the circumferential velocity V2. Thecircumferential velocity V21 of the pad 9 _(i) is set at a substantiallyconstant velocity equal to or close to the circumferential velocity V2of the second roller 12. That is, while at least the pad 9 _(i) is incontact with the second roller 12 via the second web and the like or atleast the pad 9 _(i) places the first web W1 on the second web W2, thepad 9 _(i) moves at the substantially constant circumferential velocityV21 substantially equal to V2. In other words, during a period from atime when the second web W2 on the pad 9 _(i) starts receiving the firstweb W1 to a time when the second web W2 finishes receiving it, the pad 9_(i) moves the constant circumferential velocity V21 (≈V2). Thedifference in velocity prevents the first web W1 and the second web W2from being shifted from each other, and exactly places the first web W1at a predetermined position of the second web W2.

The circumferential velocity of the pad 9 _(i+1) becomes V31 at a pointB where the pad 9 _(i+1) releases the second web W2. FIG. 5B is a sideview showing the enlarged vicinity of the point B. The pad 9 _(i) movesat a substantially constant circumferential velocity V31 at least duringa period from a time slightly before the pad 9 _(i+1) adjacent to thepad 9 _(i) releases the second web W2 to a time when the pad 9 _(i)releases the second web W2 (FIG. 5B). The reason for this is to minimizethe fluctuation in velocity of the released second web W2. For example,in the case where the circumferential velocity of an embossing roller 5is V3, the circumferential velocity V31 becomes substantially equal toV3.

When or after the circumferential velocity of the pad 9 _(i) becomesmaximum in the vicinity of the point A in FIG. 5A, the pad 9 _(i)receives the second web W2. If the pad 9 _(i) receives the second web W2before the circumferential velocity of the pad 9 _(i) becomes maximum,the interval between adjacent pads is increased, which may damage thesecond web W2. As the operation of the pad 9 _(i), the pad 9 _(i) maymove at a maximum circumferential velocity, for example, during a periodfrom the point B to the point A. In this case, a region from the point Bto the point A can be dealt with as one region. That is, in the presentembodiment, the circumferential velocity of the pad may becomesubstantially constant at least at two points.

It is preferable that the apparatus is provided with a directing part sothat the loose portion Wa in FIG. 1 becomes loose exactly toward thecenter of the rotation apparatus 1.

The directing part may be, for example, a mechanism for jetting air or amechanism for pushing the loose portion Wa of the web toward the centerof the rotation apparatus 1. Alternatively, the directing part may be amechanism for sucking the web W toward the center of the rotationapparatus 1 by vacuum suction. In the case where the directing part is amechanism for jetting air, one or a plurality of directing parts may beprovided. Furthermore, in the case where the directing part is amechanism for pushing the loose portion Wa, one or a plurality ofdirecting parts may be provided. By providing a plurality of directingparts, the loose portion Wa can be bent exactly toward the center of therotation apparatus 1. In the present embodiment, the loose portion Wamay have a shape dented toward the center of the rotation apparatus 1due to the weight of the second web W2.

Next, a folding operation will be described. When the second web W2 issucked to be held on the surface of the pad 9 _(i) at the receivingposition RP, the second web W2 is transported along the pad 9 _(i) ofthe rotation apparatus 1. When the pad 9 _(i) is rotated from thereceiving position RP to the contact point 0, the interval between thepads 9 _(i) is decreased. Because of this, the loose portion Wa isformed in the second web W2. Furthermore, the loose portion Wa is foldedinto two to form a folded portion Wb.

The rotation apparatus for conducting the above-mentioned “folding” isnot limited to the rotation apparatus 1. For example, an apparatusdescribed in Japanese Patent Application No. 2001-545183 A may be used.The present invention is intended to place an elastic memberintermittently on a web. Therefore, the second web W2 is not necessarilyfolded completely. Furthermore, depending upon the shape of the pad 9_(i), the second web W2 may have a loop shape.

The folded second web W2 is attached to be stacked on the first web W1at non-folded portions Wc before and after the folded portion Wb. Thatis, the elastic member F is not cut until the elastic member F is placedand fixed between the first web W1 and the second web W2. Therefore, thestretched elastic member F hardly shrinks on the second web W2. When thesecond web W2 is stacked on the first web W1, the first web W1 is notplaced on the folded portion Wb folded between the pads 9 _(i) and 9_(i+1) adjacent to each other in the vicinity of the contact point 0.When the interval between the pads 9 _(i) and 9 _(i+1) is increased asshown in FIG. 2, only the elastic member F is exposed as shown in FIG.3A.

As shown in FIG. 1, during β from a time when the first web W1 isattached to the second web W2 to a time when the first web W1 isreceived, suction of air through the suction holes 12 a of the secondroller 12 may be stopped or air may be discharged through the suctionholes 12 a. The purpose of this is to attach the first web W1 to thesecond web W2 smoothly.

The exposed elastic member F in FIG. 3A is cut with a cutter. In thecase where the elastic member F can be cut with a light cutter, a lightcutter 4 shown in FIG. 2 is used. The light cutter 4 has a rotatablecover, and a slit 42 is formed at a part of the cover. The cover 41 withthe slit 42 is rotated, whereby infrared rays are radiatedintermittently from a light source 40 to the elastic member F to cut itat a predetermined pitch. When the elastic member F is cut with thelight cutter 4, there is no possibility that the webs W1 and W2 aredamaged by heat from the light cutter 4, since the elastic member F isaway from the loose portion Wa. The elastic member F may be cut with apressure, heat, UV-rays, a laser or at least two of them. Furthermore,the elastic member F may be cut with an ultrasonic wave.

Hereinafter, an example of cutting the elastic member F with a cutterwill be described. FIG. 11A is a view showing a cutting machine 43 thatis an example of a cutter. The cutting machine 43 has a rotatable roller44 and a blade 45 placed at the roller 44. The distance between therotation center of the roller 44 and the center of the rotationapparatus 1 is hardly changed. The blade 45 can cut the elastic member Fpositioned on the loose portion Wa between the pads 9 _(i) and the pad 9_(i+1), when the roller 44 is rotated. The rotation of the roller 44 ischanged in accordance with the rotation of at least one of the pad 9_(i) and the pad 9 _(i+1). The blade 45 may have a linear shape (FIG.11B) or may be in a jagged shape (FIG. 11C). Furthermore, the blade 45may be reciprocated in the direction of the rotation axis of the roller4.

FIG. 11D shows another cutting machine 46. The cutting machine 46includes a rotatable large roller 47, a rotatable small roller 48attached to the large roller 47, and a blade 49 placed at the smallroller 48. The blade 49 of the cutting machine 46 can cut the elasticmember F positioned on the loose portion Wa between the pad 9 _(i) andthe pad 9 _(i+1), when the large roller 47 and the small roller 48 arerotated. The rotations of the large roller 47 and the small roller 48are changed in accordance with the rotation of at least one of the pad 9_(i) and the pad 9 _(i+1). As shown in FIG. 11D, when the blade 49reaches the bottom dead point, the tip end of the blade 49 is preferablydirected to the center of the rotation apparatus 1. Furthermore, in thesame way as in the blade 45, the blade 49 may have a shape as shown inFIG. 11B or 11C, and may be reciprocated in the direction of therotation axis of the large roller 47 or the small roller 48.

The rotation apparatus 1 may be provided with scissors instead of thecutting machine. After the second web W2 is stacked on the first web W1,and the interval between the pad 9 _(i) and the pad 9 _(i+1) is slightlyincreased, the scissors may enter between the pad 9 _(i) and the pad 9_(i+1) to cut the elastic member stretched between the pad 9 _(i) andthe pad 9 _(i+1). The scissors may enter between the pad 9 _(i) and thepad 9 _(i+1) in accordance with the rotation of at least one of the pad9 _(i) and the pad 9 _(i+1). In order for the scissors to perform suchan operation, at least one of a cam mechanism and a link mechanism maybe used.

In FIG. 1, the circumferential velocity of the pad 9 ₃ becomes avelocity V31 (V31>V21) at a releasing position SP where the pad 9 ₃releases the second web W2. Therefore, the interval between the pads 9 ₃and 9 ₄ is increased from the contact point 0 to the releasing positionSP. Therefore, the tension stress and elongation of the elastic member Fare increased from the contact point 0 to the releasing position SP.When the elastic member F is cut with the light cutter 4 in this state,cutting becomes easy. At the releasing position SP, a stack N1 in FIG.3B, in which the webs W1 and W2 and the elastic member F are stacked, isin the state before the folded portion Wb is folded.

Herein, during a from the releasing position SP to the receivingposition RP, suction through the suction holes 10 may be stopped, andair may be discharged through the suction holes 10. The purpose of thisis to smoothly transfer the stack N1 in a downstream direction.

As shown in FIG. 1, an embossing roller 5 may be provided downstreamfrom the releasing position SP. The stack N1 in FIG. 3B is sent to theembossing roller 5. A plurality of convex portions 51 are arranged onthe embossing roller 5, and at least the elastic member F of the stackN1 is cut with the convex portions 51. Because of this, as shown in FIG.4A, the stack N1 is obtained in which the shrinking force of a part ofthe elastic member F interposed between the first and second webs W1 andW2 is suppressed. An adhesive is not basically applied to a portion CPwhere the shrinking force of the elastic member F is suppressed by theembossing roller 5. The reason for this is to protect the shrinking ofthe elastic member F. However, in order to control the shrinking of theelastic member F, some adhesive weaker than usual may be applied.

A portion represented by a solid line in FIG. 4B shows an example of adisposable diaper produced by the production method of the presentinvention. In the stack N1, at least a part of an absorber C is fixed atthe portion Wb of the stack N1 where the elastic member F is not placed.The other end of the absorber C is connected to another stack N2represented by a broken line. The absorber C is folded into two, and theportion CP of the stack N1 comes into contact with a correspondingportion of another stack N2, whereby continuous disposable diapers canbe produced. Another stack N2 may have the same configuration as that ofthe stack N1. Furthermore, in the case where the absorber C is foldedinto two, and the portion CP of the stack N1 comes into contact with thecorresponding portion of another stack N2, whereby the stacks N1 and N2are stretched in a flow direction, even if the elastic member F isplaced at the portion CP, the above connection can be conducted.

Furthermore, the following may also be possible: when the elastic memberF is cut so that a trim is not generated as shown in FIG. 12, and thephase of one web thus cut is shifted by substantially ½ from the otherweb, whereby the web W2 shown in FIG. 4B is formed. As a method forshifting a phase, one web may be allowed to pass through a dummy rollerto cause a delay from the other web.

Embodiment 2

Next, Embodiment 2 will be described. A production apparatus shown inFIG. 6 is capable of placing at least three kinds of elastic members F1to F3 for a leg gathering on a wearing article, as shown in FIG. 9A.

(1) Arrangement State of Elastic Members:

First, as shown in FIG. 7, the configuration and operation of thepresent apparatus for obtaining an arrangement state of elastic members,in which first and second elastic members F1 and F2 are placed on websW1 and W2, will be briefly described.

The present apparatus includes a first roller 11 for placing a firstelastic member 1 for a waist gathering and a guide unit 23 for placing asecond elastic member 2 for a leg gathering. The guide unit 23 iscapable of arranging the second elastic member F2 for a leg gathering ina curved shape or a linear shape by being reciprocated in the axisdirection of a second roller 12 with, for example, a cam or a servomotor. U.S. patent application Ser. No. 10/095,959 discloses an exampleof the guide unit 23. The second elastic member F2 may be cutmechanically with scissors, a blade, or the like provided at the roller.FIGS. 11A to 11D show examples of a cutter. The first elastic member F1may not be a thermoplastic elastic member. In this case, the firstelastic member F1 can be cut with scissors, a blade, or the like in thesame way as in the second elastic member F2. Furthermore, the first andsecond elastic members F1 and F2 may be cut with the same scissors,blade, or the like. In the steps until here in Embodiment 2, the otherconfiguration is the same as that of Embodiment 1. Like parts aredenoted with like reference numerals, and the detailed description anddrawings are omitted here.

After being interposed and fixed between the first and second webs W1and W2, the first and second elastic members F1 and F2 are cut to bearranged as shown in FIG. 7.

In some disposable wearing articles, an elastic member for a leggathering is placed on a crotch portion. Therefore, such a portioncontrasts to cause an unsatisfactory feeling during wearing. In order toavoid this, the elastic member on the crotch portion is cut so as toshrink, whereby the elastic member on the crotch portion can be madeshort to some degree. However, it is impossible to completely eliminatethe elastic member on the crotch portion, so that an unsatisfactoryfeeling may still remain.

In contrast, when the second elastic member F2 for a leg gathering isplaced as shown in FIGS. 10A, 10C, and 10E, the second elastic member F2can be eliminated from the crotch portion G. FIGS. 10A, 10C, and 10Eshow the second elastic member F2 interposed between the first web W1and the second web W2 on adjacent pads 9, wherein a part of the web W2is interposed between the adjacent pads 9.

For example, as shown in FIGS. 10A and 10 c, a folded portion Wb isformed on the crotch portion G of the first web W1, and the secondelastic member F2 is placed on non-folded portions Wc. Thereafter, thesecond elastic member F2 striding across the adjacent pads 9 is cut. Asa result, the second elastic member F2 is not placed on the crotchportion G, as shown in FIGS. 10B and 10D.

Furthermore, as shown in FIG. 10 e, when a non-coated portion Df with noadhesive applied thereto is provided in the non-folded portion Wcadjacent to the vicinity of the folded portion Wb, after the secondelastic member F2 is cut, a portion of the second elastic member F2 thatis not sufficiently attached to the non-folded portion Wc shrinks (FIG.10F). Full-circle pants may be produced by such adjustment of anadhesive. Some adhesive may be applied to the non-coated portion Df. Inthis case, the second elastic member F2 shrinks slowly without beingfixed to the non-folded portion Wc, and finally, the second elasticmember F2 can be eliminated from the crotch portion G.

The adhesive only needs to be applied to a portion where the secondelastic member F2 is placed. As a coating method, an adhesive may beapplied in an annual shape to at least one of the first and second websW1 and W2 with a coater or the like. Furthermore, guns with a pluralityof valves are placed in a direction across the first web W1 so thatopening/closing of the valve may be controlled by the flow speed of atleast one of the first web W1 and the second web W2 and the coatingshape. In the case of using such guns, an adhesive can be applied inarbitrary regions partitioned in a matrix.

(2) Attachment State of an Absorber:

An absorber C is arranged and attached to the webs W1 and W2 in theabove-mentioned arrangement state of the elastic members by a turnapparatus 30. Thereafter, a third elastic member F3 for a waistgathering is placed to form an attachment state of an absorber as shownin FIG. 8.

The turn apparatus 30 is provided with a plurality of suction pads 30 paround a drum (not shown). The suction pads 30 p are rotated in an arrowdirection while changing the posture of the absorber C by 90° byturning. As the turn apparatus 30, for example, an apparatus asdisclosed by International Publication No. WO 01/44086 or U.S. patentapplication No. US 2002/0103468 may be used.

(3) Both-Edge Folded State:

Thereafter, the webs W1 and W2 with the absorber attached thereto havetheir folding portions E on both edges folded inward at a position oftwo-dot dash lines L₂ shown in FIG. 8 by a folding apparatus 31. Afterboth edges of the webs W1 and W2 are folded, a leg hole Lh is cut outwith a leg hole cutter 32 (FIG. 6), whereby a both-edge folded stateshown in FIG. 9A is formed. The leg hole cutter 32 may be placedupstream from the turn apparatus 30. In such a configuration, it alsobecomes possible to produce a disposable wearing article in which a partof the absorber C extends out to the leg hole Lh portion.

(4) Two-Folded State:

After folding, the webs W1 and W2 are folded into two at a folding lineB by a two-folding apparatus 33, whereby the webs W1 and W2 are foldedinto two as shown in FIG. 9B. As the two-folding apparatus 33, forexample, an apparatus described in U.S. Pat. No. 3,828,367, U.S. Pat.No. 5,711,832, or U.S. patent application Ser. No. 10/147,644 may beused.

Thereafter, the webs W1 and W2 folded into two have both edges L sealed(e.g., heat-sealed or sonic-sealed), as shown in FIG. 9B. Thereafter, acutting portion D represented by a two-dot dash line is cut to form anindividual disposable wearing article, e.g., pants P.

The present apparatus may form pants P from the webs W1 and W2(hereinafter, referred to as a “stacked web W”) folded into two, using adecelerating drum 34, a main drum 37, a seal roller 35, and a cutterroller 36.

Decelerating Drum 34:

As described above, although the web W has an elastic member, the web Wis moved in a stretched state so that placement of an absorber at apredetermined position, formation of a leg hole, and other processingcan be performed easily. However, in order to seal the web W and cut aseal portion, the position of the edge L only needs to be determined.This is because the state of the other portions of the web W does notinfluence a sealing step and a cutting step. Furthermore, in the sealingstep, it is preferable that a flow speed of the web W is lower so as toobtain a sufficient time for melting a part of the web W and the like.The decelerating drum can decrease the flow speed of the web W so as toobtain a sufficient time for melting the part of the web W and the like.As the decelerating drum 34, an apparatus described in JP 63-317576 A,International Publication No. WO 01/44086, or U.S. patent applicationNo. 2002/0103468 may be used.

The decelerating drum 34 is provided with a plurality of pads 34 protating in a transport direction of the stacked web W around a drum(not shown). The decelerating drum 34 receives at least an edge L at areceiving position RP from the two-folding apparatus 33 placed upstreamtherefrom, and holds it. The other portions of the web W are positionedbetween adjacent pads 34 p. The edge L is transported to a releasingposition SP, and thereafter, the edge L is supplied to the main drum 37placed downstream therefrom at the releasing position SP. While the pad34 p moves from the receiving position RP to the releasing position SP,the interval between the adjacent pads 34 p is changed to be narrow.

The pad 34 p is capable of receiving the edge L in a stretched state atthe receiving position RP, and keeping holding the edge L shown in FIG.9B. For example, the edge L may be held by sucking the edge L, pressingthe edge L with a hook, or fixing the edge L with a pin placed at thepad 34 p. On the other hand, the interval between the adjacent pads 34p, which has been increased at the receiving position RP, is decreasedbefore the releasing position SP, and a shrinking portion S excludingthe edge L shrinks in a transport direction X. In order to allow theedge L to be exactly held, the shrinking force of the elastic memberpositioned at the edge L may be weakened by an embossing roller 38. Forexample, the embossing roller 38 can cut the elastic member to apredetermined length or change the elastic configuration of the elasticmember by using at least one of heat and pressure. As the embossingroller 38, for example, an apparatus described in U.S. patentapplication No. 2002/0103468 may be used. The embossing roller 38 isplaced in a region from the rotation apparatus 1 to the two-foldingapparatus 33.

Main Drum 37:

The main drum 37 receives the web W in a mixed state where the stretchededge L and the shrinking portion S that has shrunk are presentalternately from the decelerating drum 34. The main drum 37 transportsthe web W in such a mixed state. In order to keep the mixed state, themain drum 37 may be provided with, for example, a plurality of suctionholes to suck air through the suction holes so as to suck the web W.

Seal Roller 35:

The seal roller 35 can conduct heat-sealing by heating and pressing theedge L (FIG. 9B) of the web W. More specifically, the web W is pressedby being interposed between the seal roller 35 and the main drum 37, andheated by the seal roller 35. The seal roller 35 may be provided with,for example, a heater so as to heat-seal the edge L. Furthermore, theseal roller 35 may have a horn to conduct sonic-sealing. The web Wsubjected to the above-mentioned heat-sealing is cut to individual pantsP by a cutter roller 36 placed downstream therefrom.

Formation Operation of Pants P:

Next, an operation of forming pants P from the stacked web W will bedescribed. The decelerating drum 34 continuously receives the web W ontoeach pad 34 p under the condition that the web W is stretched in a flowdirection. Herein, the pad 34 p holds the edge L (FIG. 9B) of the web Win a stretched state.

After receiving the web W, the pad 34 p having received the web W hasits circumferential velocity decreased, whereby the interval between theadjacent pads 34 p becomes narrow. Therefore, a portion S other than theedge L of the web W shown in FIG. 9B shrinks in a transport direction Xto form the shrinking portion S. On the other hand, the edge L is heldin a stretched state.

Thereafter, the main drum 37 receives the web W from the deceleratingdrum 34. At this time, the main drum 37 receives the web W in a mixedstate where the edge L in a stretched state and the shrinking portion Sthat has shrunk are present alternately. The main drum 37 transports theweb W in a downstream direction while keeping the mixed state. Duringtransportation by the main drum 37, the seal roller 35 presses and heatsthe edge L of the web W on the main drum 37. Herein, a part of the web Wshrinks, so that the transport velocity of the web becomes low. Sealingcan be conducted exactly, as the transport velocity of the web W is low.

Thereafter, the web W is cut to individual pieces with a cutter roller36 to form pants P.

As described above, according to the present invention, after beinginterposed and fixed between a first web and a second web, an elasticmember is cut. Therefore, the stretched elastic member hardly shrinks onthe second web, whereby an expected gathering is obtained.

Furthermore, according to the present invention, the elastic member iscut between adjacent first webs. Therefore, the second web and anabsorber do not become stiff between the first webs.

Furthermore, a plurality of first webs are placed on a second web underthe condition where they are away from each other. Therefore, the firstweb is not stacked on a portion where a gathering of the elastic memberis not formed, so that such a portion becomes thin and allows air topass there through. As a result, a user wearing such an article is notlikely to feel stuffy.

Furthermore, the elastic member is cut between the first webs and at aloose portion of the second web. Therefore,only the elastic member canbe cut without damaging the web.

If a pad that makes the second web loose is allowed to transport thesecond web at a substantially constant velocity during a predeterminedperiod from a time when the pad starts receiving the first web to a timewhen the pad finishes receiving it, the first web can be transferred toa predetermined position of the second web exactly.

Furthermore, if the elastic member is cut under the condition that thetension stress of the elastic member is increased, the elastic membercan be cut easily with infrared rays or the like.

Furthermore, while the web is transported under the condition that anedge (where the web is stretched) and a shrinking portion (where the webshrinks) are present alternately in a transport direction, a heatingtime for heating the edge becomes long. Therefore, the transportvelocity of the web can be increased without impairing the exactness ofheat-sealing.

Various other modifications will be apparent to and can be readily madeby those skilled in the art without departing from the scope and spiritof this invention. Accordingly, it is not intended that the scope of theclaims appended hereto be limited to the description as set forthherein, but rather that the claims be broadly construed.

1. An apparatus for producing a wearing article, comprising: means forsupplying an elastic member; means for stretching the elastic member;means for placing the stretched elastic member so that the elasticmember spreads across a plurality of first webs divided in a transportdirection; means for making a part of a second web loose in thetransport direction while transporting the second web, thereby forming aloose portion; means for placing the first web, on which the elasticmember is disposed, on non-loose portion before and after the looseportion of the second web; and means for cutting the elastic memberbetween adjacent first webs of the plurality of first webs.
 2. Theapparatus for producing a wearing article according to claim 1, wherein,in forming the loose portion, the second web is transported at asubstantially constant velocity during a predetermined period by a firstpad among a plurality of pads disposed away from each other and havingvarying movement velocities, and an interval between the first pad and asecond pad adjacent to the first pad is decreased to generate the looseportion.
 3. The apparatus for producing a wearing article according toclaim 1, wherein, in placing the first web, a first pad corresponding tonon-loose portion of the second web among the plurality of pads havingvarying movement velocities is rotated at a substantially constantvelocity.
 4. The apparatus for producing a wearing article according toclaim 1, further comprising means for placing an absorber on a regionbetween the adjacent first webs.
 5. The apparatus for producing awearing article according to claim 1, wherein a material containing, asthe elastic member, at least one of thread rubber, flat rubber,mesh-shaped rubber, a film, and a thermoplastic elastic member.
 6. Theapparatus for producing a wearing article according to claim 1, whereinthe means for cutting the elastic member cuts by adding at least heat tothe elastic member between the adjacent first webs.
 7. The apparatus forproducing a wearing article according to claim 6, wherein the means forcutting the elastic member cuts in a state where stress of the elasticmember is increased by allowing the adjacent first webs to be away fromeach other during transportation.
 8. The apparatus for producing awearing article according to claim 1, wherein the means for cutting theelastic member cuts the elastic member between the adjacent first webswith at least one of scissors and an edge.
 9. An apparatus for producinga wearing article, comprising: a roller means for supplying a pluralityof first webs divided in a transport direction at a predeterminedposition in a state where an elastic member is placed so as to spreadacross the first webs; rotation means including a plurality of pads forrotating the plurality of pads to continuously transport a second weband approach the roller means at the predetermined position; and cuttermeans for cutting the elastic member, wherein the rotation means rotatesthe respective pads of the rotation means so as to have varyingcircumferential velocities, the respective pads of the rotation meansreceive the second web at a receiving position upstream from thepredetermined position, and after receiving, an interval between theadjacent pads is decreased while the pads are rotated to thepredetermined position, whereby a loose portion is formed in the secondweb, the first webs are placed to be stacked on a surface of the secondweb on a basis of the pads at the predetermined position, an intervalbetween the adjacent pads is increased while the respective pads of therotation means are rotated from the predetermined position to areleasing position downstream from the predetermined position, and thecutter means cuts the elastic member in the loose portion while the padsare rotated from the predetermined position to the releasing position.10. An apparatus for producing a wearing article, comprising: means forsupplying a first elastic member, a first web, and a second web; meansfor stretching the first elastic member; means for cutting the first webto a predetermined length in a transport direction; means for making apart of the second web loose in the transport direction , therebyforming a loose portion; means for putting the stretched first elasticmember between the cut first webs and the second web to place the cutfirst webs on non-loose portions before and after the loose portion ofthe second web; and means for cutting the first elastic member above theloose portion.
 11. The apparatus for producing a wearing articleaccording to claim 10, further comprising means for guiding a secondelastic member for a leg gathering between the cut first webs and thesecond web.
 12. The apparatus for producing a wearing article accordingto claim 10, wherein, in forming the loose portion, the second web istransported at a substantially constant velocity during a predeterminedperiod by a first pad among a plurality of pads having varying movementvelocities, and an interval between the first pad and a second padadjacent to the first pad is decreased to generate the loose portion.13. The apparatus for producing a wearing article according to claim 11,wherein, in forming the loose portion, the second web is transported ata substantially constant velocity during a predetermined period by afirst pad among a plurality of pads having varying movement velocities,and an interval between the first pad and a second pad adjacent to thefirst pad is decreased to generate the loose portion.
 14. The apparatusfor producing a wearing article according to claim 10, wherein, inputting the stretched first elastic member, a first pad corresponding tonon-loose portion of the second web among the plurality of pads havingvarying movement velocities is rotated at a substantially constantvelocity.
 15. The apparatus for producing a wearing article according toclaim 11, wherein, in putting the stretched first elastic member, afirst pad corresponding to non-loose portion of the second web among theplurality of pads having varying movement velocities is rotated at asubstantially constant velocity.
 16. The apparatus for producing awearing article according to claim 10, further comprising means forplacing a side of an absorber on a region between the adjacent firstwebs.
 17. The apparatus for producing a wearing article according toclaim 11, further comprising means for placing a side of an absorber ona region between the adjacent first webs.
 18. The apparatus forproducing a wearing article according to claim 10, wherein a materialcontaining, as the first elastic member, at least one of thread rubber,flat rubber, mesh-shaped rubber, a film, and a thermoplastic elasticmember.
 19. The apparatus for producing a wearing article according toclaim 11, wherein a material containing, as the second elastic member,at least one of thread rubber, flat rubber, mesh-shaped rubber, a film,and a thermoplastic elastic member.
 20. The apparatus for producing awearing article according to claim 10, wherein the means for cutting thefirst elastic member cuts by adding heat to the first elastic memberbetween the adjacent first webs.
 21. The apparatus for producing awearing article according to claim 11, wherein the first and secondelastic members are cut by adding heat to the first and second elasticmember between the adjacent first webs.
 22. The apparatus for producinga wearing article according to claim 10, wherein the first elasticmember is cut in a state where stress of the first elastic member isincreased by allowing the adjacent first webs to be away from each otherduring transportation.
 23. The apparatus for producing a wearing articleaccording to claim 11, wherein the first and second elastic members arecut in a state where stress of the first and second elastic members areincreased by allowing the adjacent first webs to be away from each otherduring transportation.
 24. The apparatus for producing a wearing articleaccording to claim 10, wherein the first elastic member between theadjacent first webs is cut with at least one of scissors and an edge.25. The apparatus for producing a wearing article according to claim 11,wherein the first and second elastic member between the adjacent firstwebs is cut with at least one of scissors and an edge.